INSTALLATION GL1800 INSTRUCTIONS P/N 08T50-MCA-102justwings.com/uploads/HEATED_GRIP_WITH_THERMOSTAT.pdf · ©2005 American Honda Motor Co., Inc - All Rights Reserved. 08T50-MCA-1021-91

© 2005 American Honda Motor Co., Inc - All Rights Reserved. 08T505-MCA-1021-91 1 of 16

PARTS LIST

Accessory Application Publications No.

Issue Date

Honda Dealer: Please give a copy of these instructions to your customer.

INSTALLATIONINSTRUCTIONS

HEATED GRIPWITH THERMOSTATP/N 08T50-MCA-102

GL1800

July 2005

No. Description Qty

(1) Right grip heater 1

(2) Left grip heater 1

(3) Switch 1

(4) Heater harness 1

(5) Clearance gauge 1

(6) Grip spacer 2

(7) Wire tie 12

(8) 4 mm screw 3

(9) Switch plate 1

(10) Corrugated tube 1

(11) Sponge tape (used from the 03 model on) 1

TOOLS AND SUPPLIES REQUIREDPhillips ® screwdriverElectric drill motorHole saw (45 mm)Isopropyl alcoholPro Honda Handgrip CementScissorsScaleElectrical TapeShop towelWood blockMarkerTorque wrench

(7)

(9)

(1)

(5)

(4) (8)

(2)

(6)

(8)

(8)

(6)

TORQUE CHARTTighten all screws, bolts and nuts to their specified torques.Refer to the Service Manual for the tightening torques ofremoved parts.

Item N·m kgf·m Ibf·ft

4 mm screw 1 0.1 0.7

B Black

G Green

R Red

W White

Harness Colors

WIRING DIAGRAM

FUSE 5A

R

B/G

R B B W/B W/B R B/G

B B B B W/B R B/G

RIGHTGRIP HEATER

LEFTGRIP HEATER

HEATER SWITCH

HEATER HARNESS

MINICOUPLER(3-PIN)

(11)

(10)

2 of 16 08T50-MCA-1021-91 © 2005 American Honda Motor Co., Inc - All Rights Reserved.

1. Remove the left grip from the handlebar pipe.

HANDLE END CAP(Reuse)

SCREW(Reuse)

LEFT GRIP (Save)

SPECIFICATIONS

Power source: BatteryWattage: Approx. 35W (maximum)Heater specifications: FPC heater

(Flexible Printed Circuit)

HEATED AREA

RIGHT GRIP HEATER

FRONT

LEFT GRIP HEATER

ISOPROPYLALCOHOL

INSTALLATION

NOTE:• Disconnect the negative cable from the battery before

installing this accessory.• The memories of the tripmeter, clock, radio and

suspension system will be erased when youdisconnect the battery. Reset the memories afterreconnecting the battery.

• Tighten the screws, bolts and nuts securely.• Disconnect the throttle cable from the right grip as

instructed in the motorcycle’s Service Manual.• For secure adhesion of the grip heaters use the

recommended adhesive agent (Honda Bond A) orequivalent.

• Reinstall the removed parts on the motorcycle andmake sure that the wires and harnesses are notpinched.

• After handle grip heater installation, check the lights(e.g. right / left turn signal lights and brake lights) forproper operation.

• Be sure to open and close the throttle to check forsmooth operation after installation of the right gripheater.

• Trim the excess ends off the wire ties after attachingthem to the wire harnesses.

2. Using a Isopropyl alcohol, remove all traces ofadhesive from the handlebar pipe.

HANDLEBAR PIPE

ISOPROPYLALCOHOL


5. Liberally apply the Pro Honda Handgrip Cement to theinside of the left grip heater from the kit as shown.

Pro HondaHandgrip Cement

LEFT GRIP HEATER

NOTERead the Instructions of the steps 5 through 7 carefullybefore operation and complete the installation quicklybefore the adhesive agent cures. Use an assistant tosteady the motorcycle while installing the grips.

3. Remove the right grip from the handlebar pipe asdescribed in the Service Manual.

HANDLEBAR PIPE

SCREW (Reuse)HANDLE END CAP(Reuse)

RIGHT GRIP

4. Remove the throttle inner grip from the right grip.

THROTTLE INNER GRIP(Reuse)

RIGHT GRIP(Save)

ISOPROPYLALCOHOL

6. Spray isopropyl alcohol over the inside of the gripheater and outside of the left handlebar pipe.• This is done to ease alignment between thegrip heater and inner grip.

LEFT GRIP HEATER

ISOPROPYLALCOHOL


7. Slide the left grip heater onto the handlebar pipe asindicated.• Wipe up excess adhesive at once.

LEFT GRIP HEATER

NOTE• Do not tap on the grip end with a hammer and do not

twist the grip with force to insert the inner grip into thegrip heater. It can cause damage to the grip heaterwire.

• If the grip gets stuck halfway during installation, applyisopropyl alcohol to the gap between the grip heater.Do not try to remove the heater grip using force or ascrewdriver, etc. Damage to the grip heater wire canresult.

FRONT

LEFT GRIP HEATERHARNESS

3.8 mm

60½ (Approx)

LEFT GRIPHEATER

INSTALLATION of LEFT GRIP HEATER

HANDLEBARPIPE

8. Install the grip spacer as shown.

• There should be no clearance between the handle end capand grip spacer.

SCREW(Reuse)

GRIPSPACER

HANDLE END CAP(Reuse)

HANDLE END CAP GRIP SPACER

RIGHT GRIPHEATER

GRIP SPACER AS INSTALLED

9. Using a scale and a marker, measure and mark theharnesses of the right grip heater as shown.

RIGHT GRIP HEATER

150 mm

MARKER


10. Apply the Pro Honda Handgrip Cement to the outsideof the throttle inner grip and spread it thinly all over thesurface.

Pro HondaHandgrip Cement

11. Spray isopropyl alcohol over the inside of the right gripheater and outside of the throttle inner grip.• This is done to ease alignment between thegrip heater and inner grip.

THROTTLE INNER GRIP

ISOPROPYLALCOHOL

RIGHT GRIP HEATER

NOTERead the Instructions of the steps 10 through 12carefully before operation and complete the installationquickly before the adhesive agent cures. Use anassistant to steady the motorcycle while installing thegrips.

THROTTLEINNER GRIP

12. Using the clearance gauge provided, slide the throttleinner grip into the right grip heater up to the edge ofthe clearance gauge. Install the right grip in the reverseorder of removal.• Wipe up excess adhesive at once.

RIGHT GRIP HEATER

THROTTLE INNER GRIP

CLEARANCE GAUGERemove after installingthe inner grip.

NOTE• Do not tap on the grip end with a hammer and do not

twist the grip with force to insert the inner grip into thegrip heater. It can cause damage to the grip heaterwire.

• If the grip gets stuck halfway during installation, applyisopropyl alcohol to the gap between the grip heater.Do not try to remove the heater grip using force or ascrewdriver, etc. Damage to the grip heater wire canresult.

THROTTLE INNER GRIP

5 mm

RIGHT GRIP HEATER

• Obtain 5 mm of clearance between the right grip heaterand throttle inner grip using the clearance gauge.Install the throttle inner grip so that the right grip heaterharness is routed as shown when it is connected tothe motorcycle.

RIGHT GRIPHEATER HARNESS

FRONT

60½ (Approx)


14. Open and close the throttle to check that it movesfreely without binding.

15. Remove the left side cover and disconnect thenegative terminal from the battery.

13. Install the grip spacer and handle end cap.

SCREW(Reuse)

GRIP SPACER

HANDLE ENDCAP

(Reuse)Pro HondaHandgrip Cement

BATTERYCABLECOVER

LEFT SIDE COVER

CLIP

16. Remove the parts from the motorcycle as indicated inthe Service Manual.

SEAT

RIGHT PASSENGERGRIP

LEFT PASSENGERGRIP

BOLT

RIGHT SIDECOVER

SWITCH COVER

HANDLECENTER COVER

LEFT HANDLEPLATE

RIGHT HANDLEPLATE

LEFT SPEAKERCOVER RIGHT SPEAKER

COVERMETER PANEL

RIGHT FRONT POCKETAlso remove the left side.

RIGHT SHELTERSWITCH PANELAlso remove theleft side.

SHELTER

RIGHT COWL TRIMMOULDINGAlso remove theleft side.

- Up to 02 year model -


SWITCH COVER

HANDLECENTER COVER

LEFT HANDLEPLATE

RIGHT HANDLEPLATE

LEFT SPEAKERCOVER

RIGHT SPEAKERCOVER

METER PANEL

RIGHT FRONT POCKETAlso remove the leftside.



- From 03 to 05 year model - - From 06 year model -

LEFT HANDLEPLATE

RIGHT HANDLEPLATE

METER PANEL

RIGHT FRONT POCKETAlso remove the leftside.



SEAT

RIGHT PASSENGERGRIP

LEFT PASSENGERGRIP

BOLT

RIGHT SIDECOVER


17. Locale the “x” mark on the back side of the right shelterswitch panel. Drill a hole at the mark using an electricdrill motor and 45 mm hole saw.• Remove any burr after the hole has been

opened.

MARK

RIGHT SHELTERSWITCH PANEL

WOOD BLOCK

ELECTRIC DRILL MOTOR(45 mm HOLE SAW)

18. Remove the heater switch from the heater switchbracket.• The procedures from the steps 18 through 27

shall be applied to vehicles up to 05 year model.

19. Install the heater switch bracket to the right shelterswitch panel as shown.

20. Disconnect the radiator breather hose as shown andcut it by the dimension shown in the figure.• Before starting the work, cover the painted

surfaces with shop towels or similar, as coolantmay damage the painted surfaces if it sticks tothem. If coolant should get onto any paintedsurfaces, wash it off immediately with water.

• Perform the work only after the engine hascooled down sufficiently and the watertemperature has dropped. After the work hasbeen completed, tighten the hose band again.

21. Mark the radiator breather hose with a felt-tip markerat the dimension shown in the figure.

HEATER SWITCH BRACKET(Reuse)

HEATER SWITCH (Reuse)

SCREW (Reuse)

HEATER SWITCH BRACKET(Reuse)

4 mmSCREW

RIGHT SHELTER SWITCH PANEL (Reuse)

RADIATOR BREATHER HOSE

30 mm

BOLTLoosen.

100 mm


HOSE BAND(Reuse)

SCISSORS

MARKER


Top view

RADIATOR BREATHERHOSEPass underneath theharness boot.

HARNESS BOOT

22. Route the radiator breather hose as shown.

23. Pass the radiator breather hose through thecorrugated tube and fix the tube with tape.

24. Install the radiator breather hose in reverse order ofthe disconnection.

25. Install the right shelter switch panel provisionally andarrange so that there is no interference between theradiator breather hose and the key lock ring whenthe key is turned.

26. Remove the right shelter switch panel and removethe heater switch bracket.

27. Install the heater switch bracket to the heater switch.

KEY LOCK RING PART

RIGHT SHELTER SWITCHPANEL

CORRUGATED TUBESlide onto the radiator breatherhose.

TAPEFix the corrugated tube withtape to the radiator breather atthe marked part.


MARK

RADIATOR BREATHER HOSEpassed through the CORRUGATEDTUBE.

HOSE BAND (Reuse)

BOLTTighten.

RADIATOR BREATHER HOSEpassed through the CORRUGATEDTUBE.


28. Install the heater switch on the right shelter switchpanel using 4mm screws. Remove the paper backingfrom the switch plate and press it into place.

29. Route and connect the wire harnesses as shown.

HEATER SWITCH

SWITCH PLATERemove theadhesive backingbefore attaching.

4 mm SCREW


LEFT GRIPHEATER HARNESS

HEATER HARNESS


MOTORCYCLE’S PIPE

MOTORCYCLE’S 3-PINCONNECTOR (NATURAL)

HEATER HARNESS3-PIN CONNECTOR(RED)

RIGHT HEATERHARNESSTERMINALS(RED, BLACK)

LEFT HEATER HARNESSTERMINALS(WHITE/BLACK, BLACK)



ISOPROPYLALCOHOL

Align the end of the heater switch knob with themark on the switch panel.

KNOB






RIGHT HEATERHARNESSTERMINALS(RED, BLACK)HEATER HARNESS 3-PIN

CONNECTOR (RED)

MOTORCYCLE’S 3-PINCONNECTOR (RED)


RIGHT HEATER HARNESSTERMINALS(RED, BLACK)

HEATER HARNESSHEATER HARNESS

MOTORCYCLE’SHARNESS

SOCKET BOLT- From 03 to 05 year model -






HEATER HARNESS 3-PINCONNECTOR (RED)

MOTORCYCLE’S 3-PINCONNECTOR (RED)


RIGHT HEATER HARNESSTERMINALS(RED, BLACK)

HEATER HARNESS

- From 06 year model -


30. Secure the wire harnesses with the wire ties in the areasshown.• Turn the handlebar to the extreme right and left to check

that the wire harnesses are not pulled taut.• Push the grip heater harness into handle plate.

MOTORCYCLE’S HARNESS CLAMPSecure to the motorcycle’s pipe.

WIRE TIESSecure to themotorcycle’s harness.

WIRE TIESSecure to themotorcycle’s pipe

FUSE

MOTORCYCLE’SPIPE


WIRE TIESSecure to themotorcycle’s harness. RIGHT GRIP

HEATER HARNESS

WIRE TIESecure to the motorcycle’sharness at the marked location.

After squeezing the wire tie, check that thewire harness is not sagged or pulled taut byopening and closing the throttle several times.

After connecting, wrap an electrical tapearound the terminals.

ELECTRICAL TAPE

Route the wire harness avoiding the radiator cap;then, secure the harness with the wire tie andinstall the right shelter switch panel.

RADIATOR CAP




ELECTRICAL TAPE






FUSE RADIATOR CAP

Route the wire harness avoiding the radiator cap; then,secure the harness with the wire tie and install the rightshelter switch panel.


- From 03 to 05 year model -

SPONGE TAPEFix the harness.

RADIATOR CAP



ELECTRICAL TAPE




WIRE TIESSecure to the harness.


FUSE

RADIATORCAP

Route the wire harness avoiding the radiator cap; then,secure the harness with the wire tie and install the rightshelter switch panel.


- From 06 year model -

SPONGE TAPEFix the harness.

RADIATOR CAPCLAMPHold the bundledwire harness.


31. Reinstall all removed parts.32. Reconnect the negative cable to the battery.33. Check the following:

• Operation of the grip heaters.• Smooth operation of the throttle without binding.• Operation of all lights.

OPERATION• Do not operate the grip heater switch during driving.• Wear gloves whenever operating the handle grip

heater.• Do not operate the handle grip heater with worn or

torn surface rubber. Replace the handle grip heaterwith a new one.

• The grip heater is connected to the DC circuit fromthe battery. The grip heater is incorporated with theautomatic switch that turns ON/OFF by detecting thevoltage to prevent dead battery. Therefore, the switchcan turn OFF automatically when the battery voltagedrops, e.g. when the motorcycle comes to a halt orwhen running slowly. The switch turns ONautomatically when the battery voltage rises and themotorcycle is running at a normal driving speed.

• Note that the heater temperature is proportional tothe atmospheric temperature. Do not set the gripheater at “Hi” position when the atmospherictemperature is high (20½C or above).

• When the motorcycle is crawling along, the automaticswitch may or may not turn ON according to the batterycondition when the heater switch is turned ON.

• Use only the 5A fuse to replace the grip heater fuse.• The battery is a consumable part and the grip heater

does not operate when the battery runs down. Checkthe battery periodically and replace if necessary.

USER TROUBLESHOOTING• Check the following if the grip heaters do not operate

properly.• If the grip heaters do not operate after following the

troubleshooting procedures, contact your local Hondamotorcycle dealer.

DEALER TROUBLESHOOTING• Stop the engine and turn the main switch OFF when

you check the parts and circuits other than those ofthe grip heaters.

Symptom CheckGrip heater does notoperate at all ortemperature cannotbe adjusted properly.

1. Is the engine running?2. Is the heater switch between the

Hi and Lo positions with theengine running?

3. Check by raising the enginespeed.

Heater temperature istoo low or too high.

1. Is the heater temperature setbetween Hi and Lo?

2. Is the motorcycle frequentlyoperated at idle or low speed?

3. If the temperature is too high,move the switch to the Lo positionor turn the switch Off, or wearthick gloves.

Grip heater is partlywarmed.

1. This is not a problem. Heat isconcentrated at the finger part.

Symptom Check

Grip heater does notoperate;• Faulty grip heater• Faulty grip heater

coil• Blown fuse• Open or short circuit

in heater harness• Faulty heater switch

1. Check whether wires and cables(terminals and connectors) areconnected securely.

2. Grip heater inspectionCheck for resistance between theterminals.

Standard:Right: 2.2 ohms +/- 10%

Left : 2.2 ohms +/- 10%

3. Heater harness inspection:Check for continuity by referringto the wiring diagram.

4. If no abnormality is found after theabove checks 1, 2, and 3, but thegrip heater still does not operateproperly, replace the heaterswitch with a new one.• It is hard to check the switch in

ordinary inspection method (forcontinuity etc.) because itcontains an IC circuit.

Documents

INSTALLATION GL1800 INSTRUCTIONS P/N 08T50-MCA-102justwings.com/uploads/HEATED_GRIP_WITH_THERMOSTAT.pdf · ©2005 American Honda Motor Co., Inc - All Rights Reserved. 08T50-MCA-1021-91